Enhanced processes for optimized and sustainable tortilla-based microwave appliances and products thereby

ABSTRACT

Processes for making healthful tortilla-based products in microwave ovens allow production of crisply finished products having one-fifth of the oil of those fried in oil. Likewise, a plastic composition that is suitable for supporting or holding food during warming in a microwave oven is taught which is manufactured, for example, with FDA compliant and non-leaching materials such as polymethylpentene, glass fiber, and talc, as the major or sole ingredients. Minor ingredients, such as a dye, can also be included in the manufacture of the composition, without Bispehnol A, nor any other non-FDA-approved for food contact additives needed to optimize gustatory and textural aspects of the products. Various shapes, sizes, and configurations are offered for consideration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the full Paris Convention benefit of, and priority to U.S. Letters patent Ser. No. ______, U.S. Letters patent application Ser. No. 29/429,232, filed on Aug. 8, 2012, entitled “Microwave Taco Shell Form,” U.S. Letters patent application Ser. No. 29/437,891, filed on Nov. 21, 2012, entitled “Microwave Tostada Bowl,” and U.S. Letters patent application Ser. No. 13/624,474, filed on Sep. 21, 2012, entitled “Microwave Taco Form.” Each of said application is pending or granted and each is expressly incorporated by this reference, as if the contents of each were fully set forth herein, in their entirety.

BACKGROUND OF THE INVENTIONS

The present invention relates to processes wherein the nutritional value, and lack of the use of additional cooking oil, provides for more healthy and less fatty foods for those cooking with tortillas.

In particular, the present inventions teach that one can use appliances optimized for microwave cookery to generate resultory crisped and gustatorily preferred food products. For examples, tostadas, taco-shells, MICROSTADA®s and any number of configurations of crisped and not over-cooked microwave products, including cones, as set forth herein, illustrated within exemplary embodiments, and claimed below.

SETTING OF THE INVENTIONS

Issues associated with creating optimized products based upon tortillas abound in the known arts. A threshold issue has to do with generating consistently over time, a crunchy and tasteful product that can be quickly and efficiently reproduced. To be able to do this, without formal training as a chef, or the use of any additional oil, requires both a modicum of skill, patience and a degree of good fortune—prior to the advent of the instant teachings. In short, the present invention offers for consideration a simplified method for anyone to create healthy and simply organized tortilla-based meals, meal planning and regimes for better regulating dietary intake. Limitation of oil intake, particularly, poly-unsaturated types, is now known to be important to maintaining good health.

Likewise, those skilled in the art understand that using microwaves, or shortened radio waves which penetrate articles of food and cause heat to be generated from the friction of vibrating sub-elements of the food, is highly problematic. It is also important to note that microwaves pass through many materials within a microwave oven—without heating them. Such materials, known as microwave grade materials have benefits for usage which have been optimized according to the teachings of the present inventions, as set forth below.

Food preparation encompasses cooking, heating pre-cooked food, as might be commercially available or pre-cooked at home, and food storage. Warming of food, without significant cooking, can be used to improve flexibility of foods that are rigid, to enhance aroma, to promote melting of accoutrements associated with the food, and to achieve a temperature that is used, mainly because of custom, prior to consumption of that food. (see, e.g., Hernandez-Uribe et al (2010) Plant Foods Hum. Nutr. 65:152-157; Kulp et al (1981) Crit. Rev. Food Sci. Nutr. 15:1-48; Palacios et al (2004) J. Agric. Food Chem. 22:5978-5986).

Heating of foods such as tortillas and tacos has been accomplished with the aid of a support, such a support which temporarily functions as a stand (see, e.g., U.S. Pat. No. 4,896,820 of Harrington; U.S. Pat. No. 5,487,330 of Mooney, each of which is incorporated by this reference, as if fully set forth herein in their entirety). A disadvantage of some types of supports for food, including dishes, saddles, and stands, is that they are made of cardboard, and hence cannot be re-used. The instant teachings offer for consideration additional sustainability, in that they are re-usable with little or no clean-up. Repeated usage is important for many of the embodiments called out below.

When prior art stands have been manufactured with plastic, a disadvantage is that with heating, the result is unintended odors, flavor-changing materials and/or other impurities that issue directly from the plastic, or odors that are heat-generated within the plastic and then issue.

Polypropylene, for example, is often used for storing food, and for use in microwave ovens. However, a variety of chemicals have been identified that are responsible for odors during the heating of polypropylene (see, e.g., Rebeyrolle-Bernard and Etievant (1993) J. Applied Polymer Science. 49:1159-1164). The present disclosure addresses the need for appliances for food, such as containers, supports and stands, where chemicals associated with odors, mal-odors, and undesired flavor changes are not generated at detectable concentrations during microwave heating, or otherwise released such that resultory tortilla-based food products are impacted. There is a longstanding need in the art for reusable, plastic tortilla-based food appliances directly addressed by the instant teachings.

OBJECTS AND SUMMARY OF THE INVENTIONS

According to the present inventions, there is provided an enhanced process for optimized and sustainable tortilla-based microwave cookery, which comprises, in combination, providing a unitary apparatus effective for supporting at least a tortilla-based food article, applying a pre-determined amount of microwave-based energy driven by a temporal setting in a microwave oven to the tortilla-based food article disposed upon the unitary apparatus in a first condition, and removing the tortilla-based food article disposed upon the unitary apparatus in a second condition.

According to the present inventions, there is provided a composition that is solid at room temperature, comprising polymethylpentene, glass fiber, and talc, wherein the composition has a melting temperature that resides in the range 500-650 degrees F., wherein heating of the composition by a domestic microwave oven does not discharge a detectable smell, or impart undesired flavors or extraneous chemicals to tortilla-based products being cooked on the same.

The present disclosure provides a composition that is solid at room temperature, comprising polymethylpentene, glass fiber, and talc, wherein the composition has a melting temperature that resides in the range 500-650 degrees F., wherein heating of the composition by a domestic microwave oven does not discharge a detectable smell, flavor or Bisphenol A to a tortuilla cooked on the same. What is also provided is the above composition, wherein the melting temperature resides in the range of 530-550 degrees F. Also provided is the above composition, wherein the melting temperature is 540 degrees F.

In another aspect, what is provided is the above composition, wherein the melting temperature is indistinct, and wherein the indistinct temperature occurs as a relatively narrow range that resides within the relatively large range of 500-650 degrees F. In yet another embodiment, the present disclosure provides the above composition, wherein the melting temperature is distinct, and resides in the range of 500-650 degrees F.

Furthermore, the present disclosure provides the above composition, that comprises polymethylpentene at a first percentage (%) by weight, glass fiber at a second percentage (%) by weight, and talc at a third percentage (%) by weight, according to a ratio in Table 1, wherein the sum of the first, second, and third percentages is 100%, and wherein each percentage is determinable by weighing prior to combining the polymethylpentene, glass fiber, and talc during the process of manufacture of said composition.

Also encompassed, is an apparatus or appliance that comprises a food support or food container, wherein the food support or food container is configured for supporting or containing a food during cooking in a domestic microwave oven, wherein the food support or food container comprises the composition that is disclosed above.

What is further embraced, is an appliance that comprises a food support or food container, wherein the food support or food container is configured for supporting or containing a food during cooking in a domestic microwave oven, wherein the food support or food container comprises a composition that is solid at room temperature, the composition comprising polymethylpentene, glass fiber, and talc, wherein the composition has a melting temperature that resides in the range 500-650 degrees F., wherein heating of the composition by a domestic microwave oven does not discharge a detectable smell, as determinable by the human nose, or an undesired flavor or chemicals issuing from the same.

In another aspect, what is provided is the above appliance, wherein the composition has a melting temperature that resides in the range of 530-550 degrees F. Moreover, what is provided is the above appliance, wherein the food support or food container is configured to support a soft taco or soft tortilla. In another aspect, what is provided is the above appliance, wherein the food support or food container is configured to support a soft tortilla that comprises one or both of maize flour and wheat flour that is configured to support a tortilla that comprises a an upper face and a lower face, wherein the tortilla consists of a circular dough, wherein the circular dough can be folded in half to produce a first semicircle, a second semicircle, and a folded region generally aligned with the diameter of the tortilla, wherein the appliance comprises a unitary apparatus with an apex region that is configured to be support substantially all of the folded region that is generally aligned with the diameter of the tortilla, wherein the apex region of the unitary apparatus comprises a plurality of apertures that are configured to allow passage of steam issuing from the lower face of the soft tortilla, wherein appliance further comprises a first wall and a second wall, wherein the first wall and second wall is operably linked with the apex region of the saddle to support the apex region of the saddle, wherein the first wall comprises a first lower edge, wherein the second wall comprises a second lower edge, wherein the first lower edge of the first wall and the second lower edge of the second wall are configured to rest on a substantially flat surface, wherein the first lower edge of the first wall is substantially parallel to the second lower edge of the second wall, and wherein, in use, the first wall and second wall are angled in order to substantially avoid contact with the tortilla.

Also embraced, is the above appliance, wherein the tortilla is a soft, uncooked tortilla, as well as the above appliance, wherein the tortilla is a cooked, crunchy tortilla. Moreover, what is provided is the above appliance, wherein the substantially flat surface is the base or rotating platform of a microwave oven. In yet another aspect, what is provided is the above appliance, wherein the first wall and second wall are angled in the manner of an inverted A-frame type of configuration having a rounded ventral surface.

The present disclosure encompasses all possible combinations of the above embodiments, and encompasses all possible disclosures of each independent claim with its dependent claims. For example, what is encompassed is an invention that is the combination of: Claim 1+claim 2; or the combination of: Claim 1+claim 2+claim 3; or the combination of claim 1+claim 3+claim 4; or the combination of claim 1+claim 2+claim 3+claim 4; and the like.

As used herein, including the appended claims, the singular forms of words such as “a,” “an,” and “the” include their corresponding plural references unless the context clearly dictates otherwise. All references cited herein are incorporated by reference to the same extent as if each individual publication, patent, and published patent application, as well as figures and drawings in said publications and patent documents, was specifically and individually indicated to be incorporated by reference.

The terms “adapted to,” “configured for,” and “capable of,” mean the same thing. Where more than one of these terms are used in a claim set, it is the case that each and every one of these terms, as they might occur, means, “capable of.”

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a top perspective view of unitary apparatus according to the teachings of the present invention;

FIG. 2 is a top perspective view of unitary apparatus according to the teachings of the present invention, showing a tortilla-based product disposed thereon;

FIG. 3 is a top perspective view of unitary apparatus according to the teaching of the present invention, showing a tortilla-based product disposed thereon;

FIG. 4 a top perspective view of unitary apparatus according to the teaching of the present invention, showing more than one tortilla-based product disposed thereon;

FIG. 5 is a top perspective view of unitary apparatus according to the teaching of the present invention, having a plurality of apertures and finger slots;

FIG. 6 is a side view of unitary apparatus according to the teaching of the present invention, showing a side wall with a logo disposed thereon;

FIG. 7 is a sectional view showing circulation of heated air relative to a unitary apparatus of the present invention;

FIG. 8 likewise shows a sectional view of circulation of heated air relative to a unitary apparatus of the present invention;

FIG. 9 shows the process of lifting a tortilla-based product off of the unitary apparatus upon which the same is disposed, according to the instant teachings;

FIG. 10 shows an exemplary embodiment of a tostada bowl according to the teachings of the present invention;

FIG. 11 shows a top view of an exemplary embodiment of a tostada bowl according to the teachings of the present invention;

FIG. 12 shows a bottom view of an exemplary embodiment of an exemplary embodiment of a tostada bowl according to the teachings of the present invention;

FIG. 13 shows four views of an exemplary embodiment of a Microstada® bowl according to the teachings of the present invention;

FIG. 14 shows views of an exemplary embodiment of a Microstada® bowl according to the teachings of the present invention;

FIG. 15 shows views of an exemplary embodiment of a Microstada® bowl according to the teachings of the present invention;

FIG. 16 shows views of an exemplary embodiment of a Microstada® bowl according to the teachings of the present invention;

FIG. 17 shows an exemplary embodiment of a unitary apparatus according to the teachings of the present invention;

FIG. 18 shows an exemplary embodiment of a unitary apparatus according to the teachings of the present invention;

FIG. 19 shows an exemplary embodiment of a unitary apparatus according to the teachings of the present invention;

FIG. 20 shows an exemplary embodiment of a unitary apparatus according to the teachings of the present invention;

FIG. 21 shows an exemplary embodiment of a cardboard unitary apparatus according to the teachings of the present invention;

FIG. 22 shows an exemplary embodiment of a cardboard unitary apparatus according to the teachings of the present invention; and,

FIG. 23 shows a schematized POLYTANIUM embodiment of the present invention, not shown to scale, illustrating a process according to the instant teachings.

DETAILED DESCRIPTION OF THE INVENTIONS

The present inventor has discovered that gustatorily pleasing, crispness-optimized tortilla-based products can be created using a microwave oven, without oil having the health benefits of at least about one-fifth of the calories of those produced with oil.

Under traditional corn- or maize-based natural production methods, for example, corn is soaked in lime or ash and then boiled and made into dough. Partial baking or frying results in a “tor tilla” or “little cake” which is an unleavened and typically rounded product. Those skilled in the art understand that any product made from flour can be included in this definition.

According to the instant teachings, a unitary apparatus can then be used which is effective for supporting at least a tortilla-based food article, by applying a pre-determined amount of microwave-based energy driven by a temporal setting in a microwave oven to the tortilla-based food article disposed upon the unitary apparatus in a first condition, and removing the tortilla-based food article disposed upon the unitary apparatus in a second condition.

Referring now to FIG. 1, unitary apparatus 160 (variously referred to a “unitary apparatus,” “appliance, “microwave cooking tool,” “inverted A-frame with rounded dorsal aspect/top”) features rounded dorsal surface 161. Opposing sides 162, 163 are flat, and optionally may include a logo. Bottom edges 164, 165 dispose unitary apparatus 160 generally orthogonal to a surface upon which it rests, as in a standard microwave oven base, rotation plate or assembly, all of which are located inside of conventional microwave ovens (not shown).

FIG. 2 and FIG. 3 each show how tortilla-based products (T1,T2) are disposed across unitary apparatus 162. Finger notches 112 allow a user to remove finished products.

FIG. 4 shows unitary apparatus 1150 having tortilla-based food product (T1, T2) disposed thereon. User places T1, T2 on unitary apparatus 1150 prior to actual microwave cooking.

FIG. 5 shows unitary apparatus 163 having a plurality of apertures 130 which allow passage of heated air to pass through unitary apparatus 163. Finger notches 112 are located at proximal end 14 and distal end 16 of unitary apparatus. Legs 16, 17, 18 and 19 dispose unitary apparatus 163 orthogonally upon any microwave oven surface. Width d2 is greater than width d1 so that a proper “taco-like” configuration results. D3 shows a typical height for a standard tortilla and D4 shows the preferred length.

FIG. 6 shows a side view of unitary apparatus 163, including finger notches 112, flat wall 13 and (optionally) logo space 15. Legs. 16 and 17 and cut-out 110 at the bottom of wall 13 does not change that unitary apparatus 163 is orthogonal, yet allows heated air to circulate thereunder.

FIGS. 7 and 8 show typical air gaps 111 under unitary apparatus 160, 165, wherein the dorsal aspect of unitary apparatus 160 is narrower than unitary apparatus 165. Droplets of moisture are extruded at the bottom of each apparatus.

FIG. 9 shows user (U) using a finger F to remove tortilla-based food product via finger notch 112, when the same is in a second, or crisped, condition. Ceramics tend to accumulate heat, while POLYTANIUM™ does not.

FIGS. 10 through 15 show various unitary apparatus 166, 167, 168 which are placed within microwave oven (not shown) whereby a tortilla-based product is disposed on dorsal surfaces (FIGS. 12, 13, 14, 15 and 19), allowing the cooking process to take place.

FIG. 21 and FIG. 22 show cardboard embodiments of unitary apparatus 1210, with walls 1211, 1213 for receiving a tortilla-based food product. 1220, the ventral spaces, allow for stacking.

DEFINITIONS AND METHODS

POLYTANIUM™ for the purposes of this application is a material developed by the present inventor which is microwave grade plastic, composed entirely of FDA compliant materials (meaning those approved for food contact) which is BPA safe, microwave and dishwasher friendly and has a high heat tolerance. As prototyped and tested, it is illustrated in a plurality of the figures with the exception of FIGS. 21 and 22.

Melting point is the temperature at which a crystalline plastic melts. Due to the high and disperse molecular weights of plastics, this is usually a broad melting peak, unlike the sharp transition seen for simple molecules, for example, ice/water. The energy evolved when a plastic melts can be used to assess the level of crystallinity in a DSC instrument (Lacerta Technology, Ltd., Nottingham, Great Britain, 2-page product sheet). Just above the melting temperature (Tm), plastic is a liquid and just below the plastic is a solid.

The glass transition temperature (Tg) is the temperature where the molecules of a plastic start to become mobile. Depending on the nature of the plastic, it may soften slightly, e.g. high viscosity PVC used for extrusion, or flow easily, e.g, Polystyrene and polycarbonate. Tg is a softening point, but not a melting point (Lacerta Technology, Ltd., Nottingham, Great Britain, 2-page product sheet). Just above and just below the glass transition temperature (Tg), the plastic is a different type of solid. Below, it is hard, and above it is pliable and bendable.

Resins

In addition to polymethylpentene resin, a number of other resins are available. The present disclosure can include, or alternatively exclude, compositions and related methods that comprise one or more of the following resins. For example, what can be excluded is a composition, and related methods, that comprise polyimide resin. What can also be excluded is a composition, and related methods, that comprise one or more of a polyamide resin, a polyamide imide resin, a polyether ether ester resin, a polyalylate resin, a polyester resin, silicone rubber, an urethane resin, an epoxy resin, a phenolic resin, an acrylonitrile-butadiene-styrene copolymer (ABS), a thermoplastic elastomer, a styrene-isoprene-styrene block copolymer, a styrene-ethylene-propylene-styrene block copolymer, a styrene-ethylene-butylene-styrene block copolymer, a styrene-butadiene-styrene block copolymer, styrene-butadiene rubber, a styrene-butadiene copolymer, an acrylonitrile-styrene copolymer, a polyvinyl pyrrolidone resin, a polyvinyl alcohol resin, a polyvinyl methyl ether resin, a polyvinyl isobutyl ether resin, a polyvinyl formal resin, a polyvinyl butyral resin, a polyvinyl acetate resin, a polytrimethylene terephthalate resin, a polysulfone resin, a polysulfone resin, a polystyrene resin, a polyphenylene sulfide resin, a polyphenylene ether resin, a polypropylene resin, a polyphthalamide resin, a poly(oxymethylene) resin, a polymethyl methacrylate resin, a polymethacrylonitrile resin, a polymethoxy acetal resin, a polyisobutylene resin, a polyethylene terephthalate resin, a polyethersulfone resin, a polyethylene naphthalate resin, a polyether nitrile resin, a polyether imide resin, a polyether ether ketone resin, a polyethylene resin, a polycarbonate resin, a polybutylene terephthalate resin, a polybutadiene styrene resin, polyparaphenylene benzobisoxazole resin, a poly-N-butyl methacrylate resin, a polybenzimidazole resin, a polybutadiene acrylonitrile resin, a polyarylate resin, a polyacrylonitrile resin, a polyacrylic acid resin, natural rubber, nitrile rubber, a methyl methacrylate butadiene styrene copolymer, isoprene rubber, butyl rubber, a furan resin, an ethylene-vinyl alcohol copolymer, an ethylene-vinyl acetate copolymer, an ethylene-propylene-diene terpolymer, a cellulose propionate resin, hydrin rubber, a carboxymethyl cellulose resin, a cresol resin, a cellulose acetate propionate resin, a cellulose acetate butylate resin, a cellulose acetate resin, a bismaleimide triazine resin, cis-1,4-polybutadiene synthetic rubber, an acrylonitrile-styrene acrylate resin, an acrylonitrile-styrene copolymer, an acrylonitrile-ethylene-propylene-styrene copolymer, acrylate rubber, polylactic acid, and resins comprising polyetherimide, polysulphone, polyethersulphone, or alkyd, epoxy and diallyl phthalate. Polymethylpentene is available from, e.g., Mitsui Chemical America, Inc., Rye Brook, N.Y.

Glass Fibers

The present disclosure provides glass fibers, as described. See, for example, F. T. Wallenberger, Structural Silicate and Texturizing Silica Glass Fibers, in Advanced Inorganic Fibers Processes, Structures, Properties, Applications, F. G. Wallenberger, Ed., Kluwer Academic Publishers, 1999, pages 129-168, U.S. Pat. No. 2,571,074 of Tiede et al, U.S. Pat. No. 4,542,106 of Sproull et al, U.S. Pat. No. 5,789,329 of Eastes, each of which is incorporated herein by reference in its entirety. The present disclosure provides boron-containing glass fibers, boron-free glass fibers. Boron-free glass fibers can be derived from SiO₂—Al₂O₃—CaO—MgO. Also, they can be derived from SiO₂—Al₂O₃—CaO (F. T. Wallenberger et al (2001) Glass Fibers in ASM Handbook, Vol. 21:Composites #067881 G). Glass fibers can be high-silica fibers, e.g., with 95% SiO₂ or greater than 95% SiO₂. Glass fibers are available from, for example, Corning, Inc., Corning, N.Y.; Gordon Composites, Inc., Montrose, Colo.; Sigma-Aldrich, St. Louis, Mo. See, e.g., U.S. Pat. No. 4,325,724 of Froberg, which is incorporated herein by reference in its entirety.

The present disclosure provides glass fibers of various filament diameters, e.g., 0.8-1.2 micrometers (um), 1.2-2.5, 2.5-3.8, 3.8-5.0, 5.0-6.4, 6.4-7.6, 7.6-9.0, 9.0-10.2, 10.2-11.4, 11.4-12.7, 12.7-14.0, 14.0-15.2, 15.2-16.5, 16.5-17.8, 17.8-19.0, 19.0-20.3, 20.3-21.6, 21.6-22.9, 22.9-24.1, 24.1-25.4 um, and so on (F. T. Wallenberger et al (2001) Glass Fibers in ASM Handbook, Vol. 21:Composites (#06781 G), ASM International, Materials Park, Ohio). Also provided is a population of glass fibers that includes glass fibers of more than one of these filament diameters. Glass fibers can be chopped at one or more lengths, such as 1-2 mm, 2-5 mm, 5-10 mm, 10-20 mm, 20-30 mm, 25-50 mm, and so on. See, e.g., U.S. Pat. No. 7,153,799 of Wallenberger, and U.S. Pat. No. 6,686,304 of Wallenberger, which are hereby incorporated by reference in their entirety.

Talc

A number of inorganic particles, such as talc, are available. Talc is available from, for example, American Talc Co., Van Horn, Tex.; TALC U.S.A, Page, N. Dak.

The present disclosure can include, or alternatively exclude, compositions and related methods that comprise one or more of the following inorganic particles. For example, what can be excluded is a composition that comprises calcium carbonate. Examples of the particles controlling surface energy include inorganic particles (for example, molybdenum disulfide, graphite, precipitated calcium carbonate, ground calcium carbonate, kaolin, calcium sulfate, barium sulfate, titanium dioxide, zinc oxide, zinc sulfide, zinc carbonate, satin white, aluminum silicate, diatomaceous earth, calcium silicate, magnesium silicate, synthetic amorphous silica, aluminium hydroxide, alumina, lithopone, zeolite, hydrated halloysite, magnesium carbonate, and magnesium hydroxide), organic resin particles (for example, styrenic resin particles, acrylic resin particles, microcapsules, urea resin particles, olefin polymer particles of polyethylene, polypropylene, or copolymers containing these polymers, fluorine polymer particles such as polytetrafluoroethylene (PTFE), silicon resin particles, nylon particles, and melamine resin particles).

Ratios of Polymethylpentene, Glass Fiber, and Talc

The present disclosure provides POLYTANIUM™ composition, appliances comprising said composition, and relevant methods, where the composition is prepared from ingredients that, by weight, occur in the ratios set forth in Table 1 and Table 2. The indicated ratios are those, as measured, prior to combining and processing to form a composite. For each exemplary composition, the percentages of polymethylpentene (wt.), plus glass fiber (wt.), and talc (wt.), add up to 100%. For any given row, where an exemplary composition appears to require a summed percentage that is above “100%,” this particular disclosure is only for creating a table that is symmetrical and easier to read.

In alternate embodiments, any given percentage value can refer to that “exact” percentage, that is, the stated percentage that is actually a range that encompasses a range of plus or minus 1% of that value. For each indicated percentage value, the present disclosure also encompasses embodiments where the percentage stated in the table actually refers to a range that encompasses the next lower value in the table to the next higher value in the table. Also, what is encompassed are embodiments where the stated percentage value actually refers to that percentage plus a range of plus or minus 5%, plus or minus 10%, plus or minus 20%, plus or minus 50%, plus or minus 100%, and the like. Regarding Table 1, it is the case that up to 5% of the weight of the indicated polymethylpentene, glass fiber, or talc, can be replaced with up to 5% of that weight by an additive, such as a dye. Also, regarding Table 1, it is the case that up to 10% of the weight of the indicated polymethylpentene, glass fiber, or talc, can be replaced with up to 10% of that weight by an additive, such as a dye. Table 2 expressly discloses this kind of substitution.

TABLE 1 Exemplary amounts (percent by weight) Polymethylpentene Glass fiber Talc 90% 5% 5% 80% 10% 10% 70% 15% 15% 60% 20% 20% 50% 25% 25% 80-95% 5-15% 5-15% 60-80% 5-20% 5-20% 60-80% 5-15% 5-15% 60-80% 5-10% 5-10% 60-80% 5% 5% 10% 20% 30% 40% 60-80% 10% 5% 10% 20% 40% 60-80% 15% 5% 10% 20% 40% 60-80% 20% 5% 10% 20% 40% 60-80% 25% 5% 10% 20% 40% 60-80% 30% 5% 10% 20% 40% 60-80% 35% 5% 10% 20% 40% 60-80% 40% 5% 10% 20% 40%

TABLE 2 Additional ingredients, Polymethylpentene Glass fiber Talc e.g., a dye 90% 5% 5% 0-5% 80% 10% 10% 0-5% 70% 15% 15% 0-5% 60% 20% 20% 0-5% 50% 25% 25% 0-5% 80-95% 5-15% 5-15% 0-5% 60-80% 5-20% 5-20% 0-5% 60-80% 5-15% 5-15% 0-5% 60-80% 5-10% 5-10% 0-5%

Melting Temperature™

POLYTANIUM™ of the present disclosure, for example, in the form of a molded shape, in the form of a board, or in the form of a block, has a melting temperature (Tm) that is preferably 540 degrees F. In other embodiments, Tm is 380-390 degrees F., 390-400 degrees F., 400-410 degrees F., 410-420 degrees F., 420-430 degrees F., 430-440 degrees F., 440-450 degrees F., 450-460 degrees F., 460-470 degrees F., 470-480 degrees F., 490-500 degrees F., 500-510 degrees F., 510-520 degrees F., 520-530 degrees F., 530-540 degrees F., 530-550 degrees F., 540-550 degrees F., 550-560 degrees F., 560-570 degrees F., 570-580 degrees F., 580-590 degrees F., 590-600 degrees F., 600-610 degrees F., 610-620 degrees F., 620-630 degrees F., 630-640 degrees F., and the like. In one aspect, these indicated temperatures refer to a range, where the range encompasses the exact melting temperature of the product. In another aspect, these indicated temperatures refer to a range, where the product does not have a readily detectable exact melting temperature, and where the melting temperature is better expressed as a range. Room temperature is defined as 68-77 degrees F.

For preparing POLYTANIUM™ composition, one or more solvents may be added, for example, for promoting dispersal and mixing of the ingredients. Where a solvent is used, the compositions of Table 1 and Table 2 do not include the solvent, because it is assumed that most or nearly all of the solvent will evaporate during process used to make Polytanium. Solvents can include, for example, water, acetone, ethyl alcohol, propylalcohol, butanol, methylene chloride, tetrahydrofuran, benzene, toluene, and so on.

For preparing POLYTANIUM™ composition, ingredients can be combined, and heated for about 10 minutes, 20 min, 30 min, 40 min, 50 min, 60 min, 90 min, 120 min, 150 min, 180 min, and the like. Heating can be at, for example, 380-390 degrees F., 390-400 degrees F., 400-410 degrees F., 410-420 degrees F., 420-430 degrees F., 430-440 degrees F., 440-450 degrees F., 450-460 degrees F., 460-470 degrees F., 470-480 degrees F., 490-500 degrees F., 500-510 degrees F., 510-520 degrees F., 520-530 degrees F., 530-540 degrees F., 530-550 degrees F., 540-550 degrees F., 550-560 degrees F., 560-570 degrees F., 570-580 degrees F., 580-590 degrees F., 590-600 degrees F., 600-610 degrees F., 610-620 degrees F., 620-630 degrees F., 630-640 degrees F., 640-650 degrees F., 650-660 degrees F., 660-670 degrees F., 670-680 degrees F., 680-690 degrees F., 690-700 degrees F., and so on. Also provided are stepwise heating schemes.

Glass Transition Temperature (Tg)

POLYTANIUM™ of the present disclosure, for example, in the form of a molded shape, in the form of a board, or in the form of a block, has a glass transition temperature (Tg) that is preferably 540 degrees F. In other embodiments, Tg is 380-390 degrees F., 390-400 degrees F., 400-410 degrees F., 410-420 degrees F., 420-430 degrees F., 430-440 degrees F., 440-450 degrees F., 450-460 degrees F., 460-470 degrees F., 470-480 degrees F., 490-500 degrees F., 500-510 degrees F., 510-520 degrees F., 520-530 degrees F., 530-540 degrees F., 530-550 degrees F., 540-550 degrees F., 550-560 degrees F., 560-570 degrees F., 570-580 degrees F., 580-590 degrees F., 590-600 degrees F., 600-610 degrees F., 610-620 degrees F., 620-630 degrees F., 630-640 degrees F., and the like. In one aspect, these indicated temperatures refer to a range, where the range encompasses the exact glass transition temperature of the product. In another aspect, these indicated temperatures refer to a range, where the product does not have a readily detectable exact glass transition temperature, and where the glass transition temperature is better expressed as a range.

Exclusionary embodiments are also provided. The present disclosure can exclude any composition that possesses one of the above melting temperatures. Also, what can be excluded is any composition that has a melting temperature that is below one of the above indicated temperatures. Moreover, what can also be excluded is any composition that has a melting temperature that is above any one of the above indicated temperatures. Moreover, the present disclosure can exclude any plastic composition that contains less than 80% polymethylpentene (by weight), less than 70% polymethylpentene, less than 60% polymethylpentene, less than 50% polymethylpentene, less than 40% polymethylpentene, less than 30% polymethylpentene, as determinable prior to combining all ingredients used to manufacture the plastic composition. Also, the present disclosure excludes any plastic composition that contains less than 50% talc, less than 40% talc, less than 30% talc, less than 20% talc, less than 15% talc, less than 10% talc, less than 5% talc, less than 2% talc, and so on. Also, the disclosure can exclude any plastic composition that contains less than 50% glass fibers, less than 40% glass fibers, less than 30% glass fibers, less than 20% glass fibers, less than 15% glass fibers, less than 10% glass fibers, less than 5% glass fibers, and so on. Moreover, what can also be excluded, is any plastic composition having any combination of the above, for example, what can be excluded is a plastic composition that has less than 50% polymethylpentene, less than 5% glass fibers, and less than 5% talc. Also, what can be excluded is any plastic composition that contains greater than 20% talc, greater than 30% talc, greater than 40% talc, greater than 50% talc, greater than 60% talc, greater than 70% talc, and the like. Also, what can be excluded is any plastic composition that contains greater than 20% glass fibers, greater than 30% glass fibers, greater than 40% glass fibers, greater than 50% glass fibers, greater than 60% glass fibers, greater than 70% glass fibers, and the like.

Thermal Degradation Products

The present disclosure provides compositions, appliances comprising said compositions, and related methods, that limit the quantity of volatiles that are produced with microwave heating, that limit the production of degradation products generated by a microwave oven, and that limit the concentration of volatiles that exist prior to microwave heating. The present disclosure limits volatiles, especially those that can be detected with the human nose, to under 1 millimole/liter of air, to under 100 micromoles/L air, to under 10 micromoles/L air, to under 1.0 micromoles/L air, to under 100 nanomoles/L air, to under 10 nanomoles/L air, to under 1.0 nanomoles/L air, to under 100 picomoles/L air, to under 10 picomoles/L air, to under 1.0 picomoles/L air, to under 100 femtomoles/L air, to under 10 femtomoles/L air, to under 1.0 femtomoles/L air, and the like.

Thermal degradation products of polypropylene are described (see, e.g., Davis et al (1962) J. Polymer Science. 56:485-499; W. B. Leeming (September 1973) Thermal and Photolytic Degradation of Polypropylene, Ph.D. Thesis, Univ. Glasgow. Odors of heating polypropylene have been identified (Rebeyrolle-Bernard and Etievant (1993) J. Applied Polymer Science. 49:1159-1164). The present disclosure provides compositions, appliances comprising said compositions, and related methods, that limit the odoriferous molecules, as might be generated by heating polypropylene, to levels that are undetectable by the human nose. Thermal degradation products of polyurethane have been described, and these include tetrahydrofuran (THF), dihydrofuran, butadiene, hydrogen cyanide, carbodiimide (Grassie and Zulfiqor (1978) J. Polymer Science. 16:1563-1574). The present disclosure provides compositions, appliances comprising said compositions, and related methods, that limit the odoriferous molecules, as might be generated by heating polyurethane, to levels that are undetectable by the human nose. Thermal degradation products of polystyrene include styrene, benzaldehyde, styrene oxide, acetophenone, phenylethanol (Pffaffli et al (1978) Scand. J. Work Environ. Health. 4 Suppl. 2:22-27). The present disclosure provides compositions, appliances comprising said compositions, and related methods, that limit the odoriferous molecules, as might be generated by heating polystyrene, to levels that are undetectable by the human nose.

Melting Point Temperature and Glass Transition Temperature of Plastics

Methods for determining melting point of plastics, and for determining products released from plastics during heating, have been described (see, e.g., V. Shah (2002) Characterization and identification of plastics (Chapter 21) in Handbook of Materials Selection (ed. By M. Kutz) John Wiley and Sons, Inc., New York (pages 591-614). Melting point of plastics can be measured with Fisher-Johns melting point apparatus (V. Shah (2007) Handbook of Plastics Testing and Failure Analysis, 3^(rd) ed., Wiley and Sons, Inc., New York (pages 293-294). This apparatus is available, for example, from Cole-Parmer (Vernon Hills, Ill.) and Fisher Scientific.

Human Sensory Panel for Odors; Correlating Odors with Chemical Quantitation of Odiferous Compounds

Detecting the presence of odiferous chemicals, as well as the quantification of one or more odiferous chemicals, can be assessed by the human nose. Quantification can be in terms of, for example, micrograms/liter of air, nanograms/L of air, picograms/L of air, femtograms/L of air, attograms/L of air, and so on. Also, quantification can be in terms of micromoles/liter of air, nanomoles/L of air, picomoles/L of air, femtomoles/L of air, attomoles/L of air, and so on. The skilled artisan is able to quantify the concentrations of various volatile compounds, by way of odor. For example, 2,4,6-trichloroanisole (TCA) can be detected by way of smell, when it exists at a concentration of a few nanograms/L of air (H. Rudy. Gerstel Solutions Worldwide, No. 11, pages 9-11). To give another example, the lower limit of detection of formaldehyde in the air has been determined to be 0.03-1.0 milligrams formaldehyde per cubic meter of air (Salthammer et al (2010) Chem. Rev. 110:2536-2572). Thus, methods are readily available for the controlled assessment of detecting the presence of an odiferous compound or molecule, and for the controlled assessment of the lower level of detection of an odiferous compound or molecule, as it might occur in the air. The present disclosure provides a solid composition of Polytanium®, where heating in a domestic microwave oven, for example for a period of 1-5 minutes, fails to generate a detectable odor that issues from the Polytanium. In embodiments, the present disclosure can exclude any composition, and can exclude any plastic composition, where heating in a domestic microwave oven generates a detectable odor that issues from the composition.

Domestic microwave ovens are available from Panasonic Corp., e.g., Genius Countertop Microwave, Genius Prestige Countertop, from Amana, e.g., Amana® Radarange Countertop Microwave Oven, Black and Dekker, e.g., MY30PGCS Microwave Oven, and General Electric, e.g., GE Profile® series Countertop Microwave Oven.

Sensory panels with human subjects are used to identify odors, including odors of degradation products of polypropylene and polyethylene. These degradation products can include aldehydes, ketones, carboxylic acids, alcohols, and lactones. Published studies have demonstrated the correlation of human odor perceptions with chemical quantitation by mass spectroscopy and gas chromatography (Hopfer et al (2012) Anal. Bioanal. Chem. 402:903-913). Human sensory panels have been used for detecting and quantifying a variety of organic chemicals (see, e.g., Johnson et al (2012) PLoS ONE. 7:e32693 (7 pages); Zhou et al (1999) J. Agric. Food Chem. 47:3941-3953; Brattoli et al (2011) Sensors (Basel). 11:5290-5322).

FIG. 23 is a schematic, not drawn to scale, illustrating a non-limiting embodiment of an apparatus or appliance, that is configured to support a soft tortilla prior to microwave cooking, during microwave cooking, and also to support the crunchy cooked tortilla following cooking. Apertures at the top of the appliance allow release of steam from the lower face of the tortilla during cooking. The tortilla is not shown in the figure. The embodiment shown allows the semicircular right half and left half of the tortilla to be supported thereby, and to avoid burn-inducing and/or deleterious attachment to or over-contact with the walls of the appliance before, during, and after cooking.

The present disclosure provides exclusionary embodiments, namely, those having crenulations or wave-like patterns on opposing sides. See, for example, U.S. Pat. No. 8,061,268 of Eugene McGuinness.

FIG. 23 discloses a schematic, not-scale-drawn, non-limiting embodiment of a unitary appliance with a connected dorsal aspect (11) that is configured for holding a soft tortilla during microwave heating. With microwave heating, the soft tortilla is transformed from a first condition to a second condition, namely, cooked, and becomes crunchy (second condition). What is disclosed is appliance that takes the form of saddle (11). Unitary member has an apex/dorsal aspect (111) having a plurality of apertures (12, 13). The apertures can be arranged in a straight line, in a zig-zag arrangement, or in a random arrangement. There can be two, three, four, five, six, or more apertures. The apertures can be relatively small, for example, one millimeter in diameter, or they can be relatively large, for example a centimeter in diameter. The apertures can be round, oval, square, amorphous in shape, or they can take the form of a dotted line, or the form of a perforated line. FIG. 23 also discloses direction of steam (14) that issues from any tortilla that rests on the apex/dorsal aspect (111). Steam that issues from the right semicircular half of the tortilla and from the left semicircular half can escape laterally in an outward direction, and also can escape laterally in an inward direction. Inward movement of steam is facilitated by the fact that the unitary appliance is shaped like an inverted A-frame stand, in other words, because the semicircular halves of the tortilla that is draped over the apex/dorsal aspect (111) first wall (15) and second wall (16). First wall (15) and second wall (16) are shown. First lower edge (17) and second lower edge (18) are also shown, and these edges are configured for supporting the entire unitary apparatus on a flat surface, such as the floor of a microwave oven during heating, and a tabletop in the kitchen prior to and after microwave heating. For traditional types of hard tacos, it is important that dimension 19 is less than dimension 10.

The skilled artisan will understand that any relationships, as might be required by the claims, between the workpiece (tortilla) and the appliance (stand), can confer distinct structures, and distinct arrangements of the structures.

While the method and apparatus have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.

It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the invention both independently and as an overall system and in both method and apparatus modes.

Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these.

Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same.

Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled.

It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.

Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.

Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference.

Finally, all references listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s), such statements are expressly not to be considered as made by the applicant.

In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.

Support should be understood to exist to the degree required under new matter laws—including but not limited to United States Patent Law 35 USC §132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.

To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.

Further, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “compromise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible. 

What is claimed is:
 1. An enhanced process for optimized and sustainable tortilla-based microwave cookery, which comprises, in combination: providing a unitary apparatus effective for supporting at least a tortilla-based food article; emplacing the at least a tortilla-based food article upon a dorsal surface of the unitary apparatus, whereby it is evenly draped over the dorsal surface of the unitary apparatus; applying a pre-determined amount of microwave-based energy driven by a temporal setting in a microwave oven to the tortilla-based food article disposed upon the unitary apparatus in a first condition; and, removing the tortilla-based food article disposed upon the unitary apparatus in a second condition; and repeating the process as frequently as needed.
 2. The enhanced process for optimized and sustainable microwave cookery of claim 1, wherein said unitary apparatus stands in a generally orthogonal relationship to a surface upon which is it placed, within a microwave oven.
 3. The enhanced process for optimized and sustainable microwave cookery of claim 2, wherein the first condition is soft in texture and not rigid.
 4. The enhanced process for optimized microwave cookery of claim 3, wherein the second condition is cooked to a crisped texture without burning, and wherein the temporal setting for the microwave oven is at least about one minute and thirty seconds.
 5. Products, by the process of claim 4, configured in at least one shape from the group consisting of tacos, tostadas, Microstadas®, tacostadas, bowls, and cones.
 6. A composition upon which a tortilla-based product may be disposed within a microwave oven, which is solid at room temperature, comprising polymethylpentene, glass fiber, and talc, wherein the composition has a melting temperature that resides in the range 500-650 degrees F., wherein heating of the composition by a domestic microwave oven does not discharge a detectable smell, flavor or undersired chemical residue.
 7. The composition of claim 6, wherein the melting temperature resides in the range of 530-550 degrees F.
 8. The composition of claim 6, wherein the melting temperature is 540 degrees F.
 9. The composition of claim 6, wherein the melting temperature is indistinct, and wherein the indistinct temperature occurs as a relatively narrow range that resides within the relatively large range of 500-650 degrees F.
 10. The composition of claim 6, wherein the melting temperature is distinct, and resides in the range of 500-650 degrees F.
 11. The composition of claim 6, that comprises polymethylpentene at a first percentage (%) by weight, glass fiber at a second percentage (%) by weight, and talc at a third percentage (%) by weight, according to a ratio in Table 1, wherein the sum of the first, second, and third percentages is 100%, and wherein each percentage is determinable by weighing prior to combining the polymethylpentene, glass fiber, and talc during the process of manufacture of said composition.
 11. An appliance that comprises a food support or food container, wherein the food support or food container is configured for supporting or containing a food during cooking in a domestic microwave oven, wherein the food support or food container consists essentially of at least one material selected from the group of POLYTANIUM™, glass, ceramic, and cardboard.
 12. An appliance that comprises a food support or food container, wherein the food support or food container is configured for supporting or containing a food during cooking in a domestic microwave oven, wherein the food support or food container comprises a composition that is solid at room temperature, the composition comprising polymethylpentene, glass fiber, and talc, wherein the composition has a melting temperature that resides in the range 500-650 degrees F., wherein heating of the composition by a domestic microwave oven does not discharge a detectable smell, impact an undesired flavor, nor generate chemical residue.
 13. The appliance of claim 12, wherein the composition has a melting temperature that resides in the range of 530-550 degrees F.
 14. The appliance of claim 12, wherein the food support or food container is configured to support a soft tortilla.
 15. The appliance of claim 12, wherein the food support or food container is configured to support a soft tortilla that comprises at least one of maize flour and wheat flour.
 16. The appliance of claim 12 that is configured to support a tortilla that comprises a an upper face and a lower face, wherein the tortilla consists of a circular dough, wherein the circular dough can be folded in half to produce a first semicircle, a second semicircle, and a folded region generally aligned with the diameter of the tortilla, wherein the appliance comprises a unitary apparatus with an apex region that is configured to be support substantially all of the folded region that is generally aligned with the diameter of the tortilla; wherein the apex region of the saddle comprises a plurality of holes that are configured to allow passage of steam issuing from the lower face of the soft tortilla; wherein appliance further comprises a first wall and a second wall, wherein each of the first wall and second wall is operably linked with the apex region of the unitary apparatus to support the apex region of its unitary apparatus; wherein the first wall comprises a first lower edge; wherein the second wall comprises a second lower edge; wherein the first lower edge of the first wall and the second lower edge of the second wall are configured to rest on a substantially flat surface; wherein the first lower edge of the first wall is substantially parallel to the second lower edge of the second wall; and, wherein, in use, the first wall and second wall are angled in order to substantially create a finished product with dimensions including a conventionally-sized opening for a hard taco shell.
 17. The appliance of claim 12, wherein the tortilla is a soft, uncooked, or partially cooked tortilla.
 18. The appliance of claim 12, wherein the tortilla is a cooked, crunchy tortilla.
 19. The appliance of claim 12, wherein the substantially flat surface is the floor or rotating platform of a microwave oven.
 20. The appliance of claim 12, wherein the first wall and second wall are angled in the manner of an inverted A-frame having a rounded dorsal aspect, which has a width disposed between the origins of first and second walls defined by its apex. 